Yea, I sat through sooooo many of those videos.... and taken a bunch of tests about them. Found a mistake on a test form once at a large plant in PA and that caused a whole bunch of nonsense. The person giving the test just wanted me to correct my "mistake" and I refused. It ended with a "we've done hundreds of these and you are the only one that had the balls to say anything." Seems that everyone else just went with the flow.
It was the same stuff at every place. Same rules etc. The huge exception was the GM plant in Massena, NY. They did engine block castings (fascinating lost foam casting) and the fork lifts had the right of way.... It was safer to get run over then for them to abruptly stop with a large cauldron of molten aluminum.
That place also had molten aluminum brought to them... I saw the flatbed truck with this big vat on the back. First I thought they were just bringing it from Alcoa and that was just around the traffic circle from them. Turned out they were bringing it from Seneca Falls, NY, about 200 miles away... Just trucked it right up Rt. 81. I can't even imagine what would happen if they crashed.
I have been to Messena PRE (dirty, loud, hot, kinda dangerous) lost foam and post (cleaner, quieter, safer, etc) .
I became was familiar with the technology when we started it in Spring Hill to do Saturn engine blocks/other parts. Lets just say it took a LONG time to get that right in production volume/quality etc. Then gradually GM went "large" with the process after a whole lotta headaches with it.
Yep, transporting moltem aluminum .. i knew it was happening there but forgot where it was coming from 200 miles away. I guess i dunno if it still goes on and why in the world would anybody wants those trucks rolling through their towns. Must be safe "enough" I guess?
For anyone not familiar with lost foam casting, it TOO is fascinating. 6 min vid (same process as vid in post #275 but better explained), narrated in English, graphics in Spanish will give you a sense of it. Who thinks of this stuff?